The present invention relates to an antenna and a method of manufacturing antennas.
The antenna comprises: —a magnetic core (1); —one or more windings (2, 3) arranged around the core (1); —and an electrically insulating base on which the magnetic core (1) provided with the winding or windings (2, 3) is arranged, the electrically insulating base integrating electrically conductive elements (20) provided for being connected to the windings (2, 3), where the electrically insulating base comprises two parts (5, 6) which are arranged in parallel, facing one another, and linked to the magnetic core (1). Each of the two parts (5, 6) provides a support portion, which support portions together constitute a support around the outer perimeter of which there is wound an external winding (4). The method comprises manufacturing the antenna of the invention by sequentially winding all the windings with a multi-axis winding machine.
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1. An antenna comprising:
at least one magnetic core;
at least one winding wound around said magnetic core; and
an electrically insulating base on which said magnetic core provided with said at least one winding is arranged, said electrically insulating base integrating electrically conductive elements connected to said at least one winding, where said electrically insulating base comprises at least two physically separated parts which are arranged, facing one another and providing a bottom seat attached to said magnetic core,
wherein:
each of said two parts provides a support portion, said support portions together constituting a support around the outer perimeter of which there is wound an external winding; and
each of said two parts has protuberances in two distal end portions, each of the protuberances including two walls which form a corner and constitute said support portions, whereby said two parts provide four corners, one gap existing between said distal end portions of each part, and another gap existing between both separated parts.
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3. The antenna according to
4. The antenna according to
5. The antenna according to
6. The antenna according to
7. The antenna according to
8. The antenna according to
9. The antenna according to
10. The antenna according to
11. The antenna according to
12. The antenna according to
13. A method of manufacturing antennas, the method comprising manufacturing an antenna according to
introducing and fixing said magnetic core in a housing demarcated by the inner faces of the four corners of the two physically separated parts of said electrically insulating base which have been obtained by molding on an intermediate element, as a metal strip, which provides said electrically conductive elements and keeps said two parts of the base attached to one another;
cutting or eliminating said intermediate element which keeps the two parts of the electrically insulating base attached to one another, and
sequentially winding with a multi-axis winding machine the at least one winding on the core and the external winding around the outer faces of at least the four corners wherein the at least one winding are first wound around the core according to axes orthogonal to one another, one of them passing through the gap existing between both parts and the other passing through the gap existing between distal end portions of each part, below segments that, as strips, join every two distal end portions to one another.
14. The method according to
15. The method according to
16. The antenna according to
17. The antenna according to
18. The antenna according to
19. The antenna according to
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This application is the US national phase application of international application number PCT/ES2015/000025, filed 24 Feb. 2015, which designates the US and claims priority to EP Application No. 14380009.2 filed 25 Feb. 2014, the contents of each of which are hereby incorporated by reference as if set forth in their entireties.
In a first aspect, the present invention relates to an antenna comprising an electrically insulating base split into two parts on which there is arranged a low coercivity magnetic core and two or more windings wound on said core, and more particularly to an antenna where the two parts of the base provide an electrically insulating support for winding one of the windings of the antenna.
A second aspect of the invention relates to a method of manufacturing antennas which comprises manufacturing the antenna of the first aspect by sequentially winding all the windings with a multi-axis winding machine.
Antennas formed by an electrically insulating base defining a housing for a one-piece magnetic core around which two windings are wound according to two axes orthogonal to one another, where the base itself defines, in its perimeter, a reel for winding a third external winding around it according to a third axis orthogonal to the other two axes, are known through U.S. Pat. No. 7,755,558B2, for example.
On the other hand, U.S. Pat. No. 8,451,184B2 discloses in the section on the state of the art (see
U.S. Pat. No. 8,451,184B2 criticizes such arrangement due to the problem involving the effect of the different windings arranged in this manner and the dimensional and geometric requirements of the common core on the characteristics of the different coils and on the capacitive couplings between windings. As a solution to such problem, U.S. Pat. No. 8,451,184B2 proposes an antenna formed by a first coil formed by an electrically insulating base split into two parts defining a housing for a first core around which two windings are wound according to two orthogonal X- and Z-axes, one in a central part of the core and the other in a groove of a perimetral part thereof, running as a discontinuous reel, and a second coil formed by a second magnetic core around which another winding is arranged according to a Z-axis, and arranged adjacent to the first coil (see
Although the solution provided by U.S. Pat. No. 8,451,184B2 constitutes, according to the inventors thereof, an antenna that may be dimensionally smaller or thinner than conventional three-axis antennas, having two cores separated from one another clearly makes the dimension according to the direction of separation of the cores greater than if only one core was used. The sensitivity range, particularly of the coil according to the Z-axis, as well as the coupling capacitances, particularly the coupling capacitance formed between the Z and Y coils, can certainly be improved.
Patent document JP2013165368A proposes an antenna formed by a one-piece core such as the one criticized in the state of the art of U.S. Pat. No. 8,451,184, i.e., a core common for the three windings, and it further proposes arranging the core with the three windings on an electrically insulating base formed by four different corner portions separated from one another which, in this case, do not define a housing for the core but rather simply a support for the core, particularly for the base of the mentioned four reel portions.
Therefore, JP2013165368A does not solve, nor does it even consider, the problem described in U.S. Pat. No. 8,451,184B2 with respect to the drawbacks of using such core for winding the three windings in terms of capacitive couplings and deterioration of the characteristics of the coils.
EP1315179A reveals a three dimensional winding arrangement having an arrangement of three coils whose axes are mutually orthogonal and intersect at a permanent point. A cubic coil bearer has raised corners with the distances between the surfaces of the raised corners and the cube surfaces corresponding at least to the coil thickness. Spaces are left between raised edges for feeding or inserting windings.
There is a need to offer an alternative to the state of the art covering the gaps found therein by providing a very small-sized antenna that performs better than the known antennas, particularly in terms of sensitivity, reduced capacitive coupling between coils, ease of manufacturing, etc.
With such purpose, in a first aspect the present invention relates to an antenna comprising:
Unlike known antennas, in the antenna proposed by the first aspect of the invention, each of the mentioned two parts of the electrically insulating base provides a support portion, which support portions together constitute a support around the outer perimeter of which there is wound an external winding.
The magnetic core is generally a ferrite core which, according to an embodiment, comprises a material selected from the group consisting of cobalt, nickel-zinc alloy, manganese-zinc alloy, amorphous cobalt and nanocrystalline cobalt.
According to a preferred embodiment, each of said two parts has protuberances in two distal end portions, each of which includes two walls which form a corner and constitute said support portions, such that said two parts provide four corners which are located at the vertices of a quadrangular perimeter, facing one another through inner faces, internally demarcating a housing for said magnetic core, and the outer faces of the four corners define said outer perimeter around which said external winding is wound.
For an embodiment, each of said two support portions comprises a C-shaped wall including two corners, such that the inner faces of the two walls are facing one another, internally demarcating a housing for the magnetic core, and the outer faces of the two walls define said outer perimeter around which said external winding is wound.
The mentioned link between the two parts and the magnetic core is generally made by means of attachment of a basal area of the magnetic core on surfaces of said parts, which are separated, using a structural adhesive.
According to an embodiment, the two parts forming the base are identical and symmetrical, made of an electrically insulating plastic material, and the mentioned electrically conductive elements are embedded in the mentioned parts and protrude from distal and/or lateral end portions thereof as projections or terminals.
According to an embodiment, the mentioned distal end portions have a rectangular prismatic configuration and are attached to one another by a straight segment with a uniform section as a strip, orthogonal to said walls, and providing the mentioned surfaces for the attachment of said basal area of the magnetic core.
According to an embodiment, said end portions of the two parts further include metal platings in a basal area for connection to a circuit by surface mounting.
For an embodiment, the external winding wound around the outer faces of at least the four corners is arranged against said outer faces without adhesive, and the wire forming this winding remains exposed to the environment.
According to a preferred embodiment, the antenna of the first aspect of the present invention integrates two windings wound on the magnetic core around respective coplanar, orthogonal X-, Y-axes, and a third external winding is wound around the mentioned outer perimeter of said support according to a Z-axis perpendicular to the two preceding axes.
For an embodiment, the magnetic core is a monolithic core and comprises a central part in the form of a quadrangular plate, having next to each of its four corners a prismatic turret protruding from the two larger faces of said central part, said turrets being linked in twos by strips, adjacent to opposite sides of the central part, said strips protruding slightly from the larger faces of said central part determining a step, said central part and said strips providing supports for corresponding windings (around the X- and Y-axes), which are spaced from one another, wound around respective coplanar, orthogonal axes and covered by an electrically insulating sheet.
Such step provides a separation between the windings according to the X- and Y-axes which reduces the capacitive coupling between axes without having to provide additional spacer elements such as polyester tape, kapton tape or the like, and allows improving operation by reducing crosstalk, as well as reducing costs.
With respect to the mentioned electrically conductive elements, according to an embodiment, these elements adopt the shape of projections protruding from one or more faces of the base and are provided for attachment with the end of one of the corresponding windings by means of welding. Each of said projections generally has a notch for winding the end of the winding around it before welding, the function of said notch being to prevent such end of the winding from slipping and coming out of the projection.
According to an embodiment, the antenna proposed by the first aspect of the invention comprises an adaptor arranged on the magnetic core integrating metal platings on a larger outer surface which continue on a side surface to establish contact with said electrically conductive elements of the parts of the electrically insulating base and with said metal platings of its larger outer surface which are intended for surface mounting of the antenna.
The walls of the support portions constituting the support around the outer perimeter of which there is wound an external winding have a thickness sized to keep the external winding separated a specific distance from the other winding or windings for minimizing stray capacitances and couplings between windings, whereby crosstalk and costs are reduced.
According to an embodiment, at least part of an upper free edge of each of the walls extends in cantilever manner, in the direction opposite the housing, forming at least one projection made of an electrically insulating material.
A second aspect of the invention relates to a method of manufacturing antennas which comprises manufacturing an antenna according to the first aspect of the invention by means of performing at least the following steps:
Keeping the two parts of the electrically insulating base attached to one another until the magnetic core is fixed thereto in the housing, particularly until the core adheres and the adhesive used is cured, means that both parts form an integral and planar assembly at all times assuring coplanarity.
The mentioned intermediate element is formed by portions of metal strips providing the mentioned electrically conductive elements which are embedded in the parts of the base and are finally cut such that said electrically conductive elements are defined protruding from the bases and constitute a small field shielding metal mass, compared to antennas with a complete base, improving the quality factor (Q) and sensitivity, reducing the mass (the metal mass as well as the mass of the base itself), which improves the drop test.
According to an embodiment of the method proposed by the second aspect of the invention, there are provided, generally from spools, long metal strips (commonly known as lead frames) with identical and equidistant fiducial holes which allow automatically centering/positioning elements in relation to same, and which provide the mentioned electrically conductive elements intended for being integrated in the parts of a plurality of bases, the injection molding of the parts of the base, the dispensing of adhesive thereon, the mounting of the core on the base and the process for the thermal curing of the adhesive for all the bases, being carried out. By keeping all the bases attached to one another using such metal strips, the problem of individual automatic feeding of the bases to the assembly line, as well as the drive, transport and centering thereof, is solved.
After the adhesive is cured, the metal strips are cut in order to split them into the mentioned portions of metal strips attaching the two pieces of a base, and the winding step is then performed.
When the manufactured antenna comprises three windings, two around the core and the external winding, according to the method of the second aspect of the present invention, the parts of the electrically insulating base used are those of the previously described preferred embodiment for which each of the two parts has protuberances in two distal end portions, each of which includes two walls forming a corner. In this case, the windings are first wound around the core according to axes orthogonal to one another, one of them passing through the gap existing between both parts and the other passing through the gap existing between the distal end portions of each part, below the segments that, as strips, join every two distal end portions to one another. Finally, the external winding is wound around the outer faces of the four corners.
For the less preferred case in which the antenna only comprises two windings, one around the core and the external winding, the parts of the electrically insulating base of the embodiment described above can also be used so that each support portion provided by each of the parts comprises at least one C-shaped wall including two corners, first winding the winding around the core in a direction parallel to the walls and passing through the gap existing between both parts, and then winding the external winding around the outer faces of the two C-shaped walls.
According to a preferred embodiment, the method comprises arranging the external winding against the outer faces of the four corners without adhesive, the wire forming this external winding being exposed to the environment, thus improving the quality factor (Q) as a result of the reduction of the diameter and length of the middle turn, and therefore of the dimensions and strength of the winding, because the wire is not a thermal adhesive wire, compared to that of the winding conventionally carried out with a thermal adhesive wire, whereby the selectivity and tuning are improved. Since the winding is smaller, its actual resonance frequency increases as the distributed capacitance of the winding decreases, whereby the frequency stability of the antenna is improved.
Since thermal adhesive wire is dispensed with, the winding process increases since there is no need to wait for the wire to adhere using a solvent or heat, which, along with the use of a high speed multi-axis winding machine, allows producing many antennas in a machine at the same time.
The foregoing and other advantages and features will be better understood from the following detailed description of several embodiments in reference to the attached drawings which must be interpreted in an illustrative and non-limiting manner, in which:
The attached drawings illustrate several embodiments of the antenna proposed by the present invention.
Particularly,
For the embodiments of
For a non-illustrated embodiment alternative to that of
Finally,
Such metal terminals T are cut, being separated from the metal strip La, Lb, once the magnetic core 1 has been fixed to the base, such that the portions which are separated from the strips La, Lb, i.e., those protruding from the ends of the parts 5, 6, define the metal projections 20.
Although
A person skilled in the art may introduce changes and modifications in the embodiments described without departing from the scope of the invention as defined in the attached claims.
Cobos Reyes, Sergio, Navarro Pérez, Francisco Ezequiel, Rojas Cuevas, Antonio, Cañete Cabeza, Claudio, Villarrubia García, Maria Del Mar
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11705260, | Jun 12 2015 | PANASONIC INTEI LECTUAL PROPERTY MANAGEMENT CO., LTD. | Magnetic device including winding and insulators, and power conversion device using the same |
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Feb 24 2015 | PREMO, S.L. | (assignment on the face of the patent) | / | |||
Sep 15 2016 | COBOS REYES, SERGIO | PREMO, SL | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 040131 | /0978 | |
Sep 15 2016 | ROJAS CUEVAS, ANTONIO | PREMO, SL | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 040131 | /0978 | |
Sep 15 2016 | VILLARUBIA GARCIA, MARIA DEL MAR | PREMO, SL | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 040131 | /0978 | |
Sep 15 2016 | CANETE CABEZA, CLAUDIO | PREMO, SL | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 040131 | /0978 | |
Sep 20 2016 | NAVARRO PEREZ, FRANCISCO EZEQUIEL | PREMO, SL | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 040131 | /0978 | |
Mar 27 2018 | PREMO S L | PREMO, S A | CHANGE OF NAME SEE DOCUMENT FOR DETAILS | 050878 | /0616 | |
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